Casing Shoe Reamer and Method

ABSTRACT

A casing shoe reamer for bypassing an obstruction in a hole or well drilled in the ground is provided. The casing shoe reamer includes an upper portion, a lower portion, and an interior volume. The upper portion can be removably secured to a casing float collar. The casing shoe reamer further includes bearings disposed therein, which enable the lower portion to rotate relative to the upper portion about its longitudinal axis. The lower portion includes at least three fins extending therefrom, each fin having an aperture disposed on a first side thereof, wherein the aperture is in fluid communication with the interior volume. An impeller is fixed within the interior volume. As a fluid is pumped into the interior volume, the fluid applies a force on the impeller and is expelled through the apertures, which cause the lower portion to rotate in a direction opposite the exiting fluid. The exited fluid and the rotational force of the lower portion enables passage of the casing shoe reamer beyond the obstruction.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 62/535,425 filed on Jul. 21, 2017. The above identified patent application is incorporated by reference herein in its entirety to provide continuity of disclosure.

BACKGROUND OF THE INVENTION

Oil and borehole mining operations frequently require drilling, which produces an open hole or a well in a ground which is accessed as part of the operation. Many such operations utilize a casing shoe reamer to pass through the open hole or the well in the ground. However, the casing shoe reamer is often impeded by obstructions, such as tight spaces, that form in the open hole or the well before or during access by the casing shoe reamer. This requires the casing shoe reamer to be retracted and disassembled without causing damage, and the hole or the well to be reconditioned with drilling. These steps are time consuming and expensive; they are characteristic of disadvantages of known approaches for bypassing an obstruction in an open hole or a well.

Therefore, there is a need in the art for an improved casing shoe reamer that can attach to a casing float collar and bypass obstructions in holes and wells, without the need to retract the casing shoe or recondition the hole or the well with drilling. The present invention addresses this unmet need.

FIELD OF THE INVENTION

The present invention relates to a casing shoe reamer.

Devices have been disclosed in the art that relate to casing shoe reamers. These include devices that have been patented and published in patent application publications. These devices have at least several shortcomings, including but not limited to, lacking an innovative and useful mechanism for both delivering a fluid to an obstruction and rotating the casing shoe reamer to bypass the obstruction. In view of the devices disclosed in the art, it is submitted that there is a need in the art for an improvement to existing casing shoe reamers. In view of the present disclosure, it is submitted that the present invention substantially diverges in structural and functional elements from devices in the art, and substantially fulfills an unmet need in the art.

SUMMARY OF THE INVENTION

In view of the disadvantages inherent in the known types of casing shoe reamers in the art, the present invention provides a new and improved casing shoe reamer, wherein the same can be utilized for navigating an open hole or a well in a ground, and for bypassing one or more obstructions in the open hole or the well in the ground.

It is therefore an object of the present invention to provide a casing shoe reamer for accessing an open hole or a well in the ground, and for bypassing one or more obstructions in the open hole or the well in the ground.

It is another object of the present invention to provide a method for accessing an open hole or a well in the ground, and for bypassing one or more obstructions in the open hole or the well in the ground, which utilizes the casing shoe reamer.

Another object of the present invention is to provide a casing shoe reamer that may be readily manufactured from materials that permit relative economy and are commensurate with durability.

Other objects, features and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTIONS OF THE DRAWINGS

Although the characteristic features of the invention will be particularly pointed out in the claims, the invention itself and manners in which it may be made and used may be better understood after a review of the following description, taken in connection with the accompanying drawings, wherein like numeral annotations are provided throughout.

FIG. 1A depicts a side perspective view of an assembled exemplary casing shoe reamer navigating a matrix of earth.

FIG. 1B depicts a bottom perspective view of the assembled exemplary casing shoe reamer navigating the matrix of earth.

FIG. 2 depicts a side perspective view of an exemplary casing float collar detached (left) and attached (right) to the exemplary casing shoe reamer.

FIG. 3 depicts a top side perspective view (left), a side perspective view (middle), and a bottom side perspective view (right) of the exemplary casing shoe reamer.

FIG. 4 depicts a close-up perspective view of a fluid exiting an aperture located on a first side of a fin extending outward from a head of the exemplary casing shoe reamer.

FIG. 5 depicts a perspective view of an impeller inside the exemplary casing shoe reamer (left), and a cutout view of the assembled exemplary casing shoe reamer (right).

DETAILED DESCRIPTION OF THE INVENTION

In one aspect, the invention provides a casing shoe reamer, comprising an upper portion and a lower portion rotatably connected to the upper portion; wherein an upper end of the upper portion is configured to be removably secured to a casing float collar; wherein the lower portion comprises a head comprising a plurality of fins extending outward from the head; wherein at least one of the plurality of fins comprises at least one aperture on a first surface of the at least one fin, wherein the aperture is fluidly connected to an interior volume of the casing shoe reamer; wherein the interior volume comprises an impeller affixed therein; wherein the impeller comprises a plurality of tapered edges configured to channel a fluid from the interior volume to the at least one aperture; whereupon delivery of a fluid from the casing float collar to the interior volume of the casing shoe reamer, the fluid applies a force on the impeller, the fluid is expelled through the at least one aperture, and the lower portion rotates relative to the upper portion about a longitudinal axis thereof.

In another aspect, the invention provides a method of bypassing at least one obstruction in a hole, comprising: inserting a casing shoe reamer into the hole; delivering a fluid to an interior volume of the casing shoe reamer; wherein the casing shoe reamer comprises an upper portion and a lower portion rotatably connected to the upper portion, wherein an upper end of the upper portion is removably secured to a casing float collar, wherein the lower portion comprises a head comprising a plurality of fins extending outward from the head, wherein at least one of the plurality of fins comprises at least one aperture on a first surface of the at least one fin, wherein the aperture is fluidly connected to an interior volume of the casing shoe reamer; wherein the interior volume comprises an impeller affixed therein; wherein the impeller comprises a plurality of tapered edges configured to channel a fluid from the interior volume to the at least one aperture, whereupon delivering the fluid from the casing float collar to the interior volume of the casing shoe reamer, the fluid applies a force on the impeller, the fluid is expelled through the at least one aperture, and the lower portion rotates relative to the upper portion about a longitudinal axis thereof.

In various embodiments, an interface between the upper portion and the lower portion comprises at least one bearing race comprising at least one bearing therein; the casing shoe reamer comprises an outer section constructed of a hard material and an inner section constructed of a drillable material; the hard material comprises a metal; the drillable material comprises a cement; the head comprises between three and six fins; the head comprises three fins; and/or the upper end comprises a plurality of threads configured to engage a set of complementary threads disposed on the casing float collar.

Reference is now made to the drawings, which depict one or more exemplary embodiments of the invention.

Referring now to FIG. 1A, there is depicted a side perspective view of an assembled exemplary casing shoe reamer navigating a matrix of earth; referring to FIG. 1B, there is depicted a bottom perspective view of the assembled exemplary casing shoe reamer navigating the matrix of earth. The casing shoe reamer 1 comprises an upper portion 2, and a lower portion 3 which is rotatably connected to the upper portion 2. An upper end of the upper portion 2 is connected to a casing float collar 4. The assembled casing shoe reamer is being lowered into a hole 6, formed within a matrix of earth 5. In the shown embodiment, the lower portion 3 includes three fins 7 extending radially outward from a head of the lower portion. Generally, the three fins 7 converge at or near a center axis of the casing shoe reamer 1, and extend radially outward from a head of the lower portion so that an outer surface of each of the three fins 7 is flush or nearly flush with an upper end of the lower portion 3. In this manner, the fins 7 are able to displace one or more obstacles in the matrix of earth, enabling the casing shoe reamer 1 to pass therethrough.

Referring now to FIG. 2, there is depicted a side perspective view of an exemplary casing float collar detached (left) and attached (right) to the exemplary casing shoe reamer. The casing shoe reamer 1 is capable of being removably secured to the casing float collar 4. In the shown embodiment, the casing shoe reamer 1 is removably secured to the casing float collar 4 by way of a plurality of threads located within an upper end of the casing shoe reamer 1, which are complementary to a plurality of threads located on a lower end of the casing float collar 4. In various embodiments, the casing shoe reamer 1 is configured to be removably secured to a standard size casing float collar 4, thereby allowing the casing shoe reamer 1 to be attached to an existing type of casing float collar 4. This modular design of the casing shoe reamer 1 helps to ensure compatibility with a range of standard or existing systems that include a casing float collar 4.

Referring now to FIG. 3, there is depicted a top side perspective view (left), a side perspective view (middle), and a bottom side perspective view (right) of the exemplary casing shoe reamer. The casing shoe reamer 1 comprises an upper portion 2 and a lower portion 3 rotatably connected to the upper portion 2, such that the lower portion 3 is capable of rotating about a vertical or longitudinal axis thereof, without detaching from the upper portion 2. In the shown embodiment, the upper portion 2 is comprised of a cylinder forming an interior therein, wherein an interior surface of the upper portion 2 comprises a plurality of threads 11 which may be used to removably secure the casing shoe reamer 1 to a casing float collar having complementary threads thereon. In the shown embodiment, the lower portion 3 comprises a base 9 connected to a head 8. Generally, the head 8 has a smaller diameter than a diameter of the base 9, the head 8 tapers into the base 9, and the head 8 comprises a plurality of fins 7 extending radially outward from the head 8. The smaller diameter of the head 8 allows the casing shoe reamer 1 to engage with an obstruction in a surrounding matrix of earth, such that all or a portion of the obstruction is between two or more fins 7; in this way, when the fins 7 rotate during operation, they disrupt, displace, or dislodge all or the portion of the obstruction to facilitate passage of the casing shoe reamer 1 therethrough. In the shown embodiment, the head 8 comprises three fins 7, each extending outward from the head 8. In the shown embodiment, an outer edge of each of the plurality of fins 7 is flush with an outer surface of the base 9, thereby enabling the fins 7 to clear a space large enough for the base 9 and the rest of the casing shoe reamer 1 to pass through the obstruction in the matrix of earth. In the shown embodiment, each of the fins 7 comprises an aperture 10 on a first surface of each of the fins 7, such that the apertures 10 are fluidly connected to an interior volume of the casing shoe reamer 1.

Referring now to FIG. 4, there is depicted a close-up perspective view of a fluid exiting an aperture located on a first side of a fin extending outward from a head of the exemplary casing shoe reamer. In the shown embodiment, the casing shoe reamer has a fluid 12 that is being delivered to an interior volume of the casing shoe reamer, which is channeled to an aperture 10 located on a fin 7, where the fluid is expelled, causing a force to be applied to the fin 7, which results in a rotation of a lower portion of the casing shoe reamer relative to an upper portion of the casing shoe reamer. Generally, rotation of the lower portion causes the fins 7 to contact and remove any obstructions, thereby allowing the casing shoe reamer to pass therethrough. The fluid 12 exiting the apertures 10 may also facilitate removal of any obstructions, such as by softening or loosening a portion of a surrounding matrix of earth, for example.

Referring now to FIG. 5, there is depicted a perspective view of an impeller inside the exemplary casing shoe reamer (left). The impeller 13 comprises a plurality of tapered edges 14, each configured to channel a fluid from an interior volume of the casing shoe reamer to at least one aperture. In the shown embodiment, the impeller 13 comprises three tapered edges 14, wherein the three tapered edges 14 are configured to channel the fluid from the interior volume of the casing shoe reamer to three apertures. When a fluid is delivered to the interior volume of the casing shoe reamer, the fluid applies a force on the impeller 13, the fluid is expelled through the at least one aperture, and the lower portion rotates relative to the upper portion about a longitudinal axis thereof.

Referring now to FIG. 5, there is depicted a cutout view of the assembled exemplary casing shoe reamer (right). In the shown embodiment, the casing shoe reamer comprises a plurality of threads 11 located on an interior of an upper end of an upper portion 2, and the plurality of threads 11 are engaged with a casing float collar 4 to form an assembly. In the shown embodiment, a lower portion 3 comprises an outer section 15 constructed of a hard material and an inner section 16 constructed of a drillable material. In the shown embodiment, the upper portion 2 comprises an outer section 21 constructed of a hard material and an inner section 22 constructed of a drillable and/or durable material capable of withstanding a force of a high pressure fluid therein. In various embodiments, the upper portion outer section 21 is made of the same material as the lower portion outer section 15, and the upper portion inner section 22 is made of the same material as the lower portion inner section 16. In various embodiments, the outer portions (15, 21) may comprise any suitable type of metal, and the inner portions (16, 22) may comprise any suitable type of cement. In the shown embodiment, the casing shoe reamer comprises four bearing races 19, each comprising one or more metal bearings 20 therein, such that the lower portion 3 is rotatable about a vertical or longitudinal axis relative to the upper portion 2. In the shown embodiment, the casing shoe reamer comprises six seals 17, configured to isolate the bearing races 19 from the interior volume 18 and an external space of the casing shoe reamer. The impeller tapered edges 14 channel a fluid in an interior volume 18 to an aperture where the fluid is expelled, as shown in FIG. 4 and described elsewhere herein, upon delivery of the fluid to the interior volume 18. Further, upon delivering the fluid from the casing float collar 4 to the interior volume 18, the fluid applies a force on the impeller tapered edges 14, and the lower portion 3 rotates relative to the upper portion 2 about a longitudinal axis thereof. The expelled fluid, combined with the rotational movement of the lower portion 3, softens and/or displaces one or more obstructions encountered in a hole, thereby enabling the casing shoe reamer to bypass the obstruction without the need to retract the casing shoe or recondition the hole with drilling.

The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and modifications and variations are possible in view of the above teaching. The exemplary embodiment was chosen and described to best explain the principles of the present invention and its practical application, to thereby enable others skilled in the art to best utilize the present invention and its embodiments with modifications as suited to the use contemplated.

It is therefore submitted that the instant invention has been shown and described in the most practical and exemplary embodiments. It should be recognized that departures may be made which fall within the scope of the invention. With respect to the description provided herein, it is submitted that the optimal features of the invention include variations in size, materials, shape, form, function and manner of operation, assembly, and use. All structures, functions, and relationships equivalent or essentially equivalent to those disclosed are intended to be encompassed by the present invention. 

I claim: 1) A casing shoe reamer, comprising: an upper portion and a lower portion rotatably connected to the upper portion; wherein an upper end of the upper portion is configured to be removably secured to a casing float collar; wherein the lower portion comprises a head comprising a plurality of fins extending outward from the head; wherein at least one of the plurality of fins comprises at least one aperture on a first surface of the at least one fin, wherein the aperture is fluidly connected to an interior volume of the casing shoe reamer; wherein the interior volume comprises an impeller affixed therein; wherein the impeller comprises a plurality of tapered edges configured to channel a fluid from the interior volume to the at least one aperture; whereupon delivery of a fluid from the casing float collar to the interior volume of the casing shoe reamer, the fluid applies a force on the impeller, the fluid is expelled through the at least one aperture, and the lower portion rotates relative to the upper portion about a longitudinal axis thereof. 2) The casing shoe reamer of claim 1, wherein an interface between the upper portion and the lower portion comprises at least one bearing race comprising at least one bearing therein. 3) The casing shoe reamer of claim 1, wherein the casing shoe reamer comprises an outer section constructed of a hard material and an inner section constructed of a drillable material. 4) The casing shoe reamer of claim 3, wherein the hard material comprises a metal. 5) The casing shoe reamer of claim 3, wherein the drillable material comprises a cement. 6) The casing shoe reamer of claim 1, wherein the head comprises between three and six fins. 7) The casing shoe reamer of claim 6, wherein the head comprises three fins. 8) The casing shoe reamer of claim 1, wherein the upper end comprises a plurality of threads configured to engage a set of complementary threads disposed on the casing float collar. 9) A method of bypassing at least one obstruction in a hole, comprising: inserting a casing shoe reamer into the hole; delivering a fluid to an interior volume of the casing shoe reamer; wherein the casing shoe reamer comprises an upper portion and a lower portion rotatably connected to the upper portion, wherein an upper end of the upper portion is removably secured to a casing float collar, wherein the lower portion comprises a head comprising a plurality of fins extending outward from the head, wherein at least one of the plurality of fins comprises at least one aperture on a first surface of the at least one fin, wherein the aperture is fluidly connected to an interior volume of the casing shoe reamer; wherein the interior volume comprises an impeller affixed therein; wherein the impeller comprises a plurality of tapered edges configured to channel a fluid from the interior volume to the at least one aperture, whereupon delivering the fluid from the casing float collar to the interior volume of the casing shoe reamer, the fluid applies a force on the impeller, the fluid is expelled through the at least one aperture, and the lower portion rotates relative to the upper portion about a longitudinal axis thereof. 10) The method of claim 9, wherein an interface between the upper portion and the lower portion comprises at least one bearing race comprising at least one bearing therein. 11) The method of claim 9, wherein the casing shoe reamer comprises an outer section constructed of a hard material and an inner section constructed of a drillable material. 12) The method of claim 11, wherein the hard material comprises a metal. 13) The method of claim 11, wherein the drillable material comprises a cement. 14) The method of claim 9, wherein the head comprises between three and six fins. 15) The method of claim 14, wherein the head comprises three fins. 16) The method of claim 9, wherein the upper end comprises a plurality of threads configured to engage a set of complementary threads disposed on the casing float collar. 